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What Are the Common Non-Conformities in FSSC 22000 Audits

By April 28, 2025No Comments

What Are the Common Non-Conformities in FSSC 22000 Audits?

Getting certified to FSSC 22000 is a major milestone for any food business—but passing the audit requires attention to detail. Understanding the most common non-conformities (NCs) can help your team better prepare, reduce risk of audit failure, and maintain ongoing certification. Here’s what you need to know.

Why FSSC 22000 Audits Matter

  • Assures customers of your food safety management commitment

  • Required by many global brands and buyers

  • Part of maintaining a GFSI-recognized certification

  • Involves review of ISO 22000, sector-specific PRPs (e.g. ISO/TS 22002-1), and FSSC Additional Requirements

Types of Non-Conformities in FSSC 22000

  • Minor NCs: A deviation that does not affect food safety directly but must be corrected

  • Major NCs: A significant deviation that could affect food safety or system effectiveness

  • Critical NCs: Immediate threat to food safety or certification—may result in suspension

Most Common FSSC 22000 Non-Conformities

1. Incomplete or Outdated Hazard Analysis

  • Hazard analysis not covering all steps or lacking justification

  • Risk assessments not updated with process or ingredient changes

  • Missing biological, chemical, or physical hazard controls

2. Poorly Defined Critical Control Points (CCPs)

  • Inadequate identification or justification of CCPs

  • Missing critical limits or ineffective monitoring procedures

  • No corrective action plan in place for CCP failures

3. Weak Prerequisite Program (PRP) Implementation

  • Incomplete cleaning and sanitation procedures

  • Inconsistent pest control records

  • Inadequate personnel hygiene controls

4. Insufficient Validation and Verification Activities

  • No evidence of validation of CCPs or process controls

  • Lack of internal audits or poorly documented verification results

  • Infrequent or missing management reviews

5. Incomplete Traceability and Recall Procedures

  • No mock recall conducted or documented

  • Traceability system not covering all inputs and outputs

  • Delays in identifying affected batches during a test recall

6. Documentation Gaps

  • Outdated or conflicting procedures

  • Missing records for monitoring or training

  • No control over document versioning and approvals

7. Lack of Training and Competency Records

  • No proof of training for food safety team members

  • Staff not aware of their food safety responsibilities

  • Incomplete or unstructured training programs

8. Failure to Address Non-Conformities and Corrective Actions

  • Recurring issues with no root cause analysis

  • No timeline or documentation of corrective actions taken

  • Lack of preventive measures to avoid recurrence

9. Inadequate Allergen Management

  • Cross-contact risks not identified or controlled

  • Incomplete cleaning validation after allergen changeovers

  • Poor labeling practices or unverified supplier claims

10. Not Meeting FSSC Additional Requirements

  • Poorly implemented food defense and food fraud vulnerability assessments

  • Lack of environmental monitoring in high-risk areas (if applicable)

  • Failure to notify certification body of significant changes

Tips to Avoid Non-Conformities

  • Conduct internal audits regularly and objectively

  • Keep all documents, records, and plans updated and accessible

  • Train your food safety team on the latest FSSC requirements

  • Perform mock recalls and food fraud assessments annually

  • Engage top management in regular food safety reviews

  • Work with an experienced consultant or certification coach

Final Thoughts
Understanding and preventing common FSSC 22000 non-conformities is the key to audit success and ongoing certification. A proactive food safety culture, strong documentation, and continuous improvement mindset are essential for passing with confidence.

Need Help Preparing for Your FSSC 22000 Audit?
At CAYS Scientific, we help food businesses prepare, implement, and maintain FSSC 22000 certification. Our services include:
✅ Gap assessments and audit preparation
✅ PRP development and food safety documentation
✅ Internal auditor training and mock audits
✅ Non-conformity correction and continuous improvement support

📞 Contact CAYS Scientific today to ensure you’re 100% audit-ready—no surprises, just success.

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